Manufacture of steel alloys



Patented July 15, 1930 pm'ran STATES PATENT; OFFICE- EENBY C. BIG-GE AND PERCY G. PARIS, F BETHLEHEM, PENNSYLVANIA, ASSIGNORS '10 BETHLEHEM STEEL COMPANY mnmrracrnnn or szrnnr. ALLOYS No Drawing.

Our invention relates to a duplex process of manufacturing alloy steels, which com-, prises reducing ore of the alloying metal in a furnace, an excess of reducing agent being employed, which excess enters the reducedmetal; transferring the reduction product to a second furnace for refining, which refining comprises the addition of an excess of ore whereby excess reducing agent in the metal 0 is decreased; running off most of the refined metal, leaving the slag, which contains the excess ore, in the furnace; adding ore and an excess of reducing agent to obtain a product similar to that first obtained in the first fur- 35 nace; and then transferring this reduction product to the first furnace for refining; The significant feature of our invention is the carrying out of the two steps of the process, that is the reduction and the refining, in two 2 furnaces in such'manner that the refining in one furnace is followed by a reduction'in the same furnace with a slag resulting from the refining operation, the two furnaces being alternately employed in. this manner: a refining operation in one furnace followed by a reduction in the same furnace to produce a product which is refined in the other furnace followed by a reduction in that furnace and soon, the second furnace, being therein diluted'with' a suitable quantity of low carbon steel scrap, which has already been melted inthis'second furnace and a final addition of chrome ore inexcess of the actual requirements is made to the bath for the removal of the silicon and the carbon. At'thecompletion of the heat, the major portion of the low carhon, low silicon chromium steel bath is tapped off to a ladle,the remainder, together with its j supernatant chromiferous slag, is retained 40 in the electric furnace and is utilized as a fusion bath for a subsequent charge of chrome ore and silicon reducer. From this, it is evident that'the refining furnace'for one charge becomes the reduction furnace for the succeeding charge, the product of said reduction furnace being then transferred to the first named furnace, (previously used for the reduction step) for the final alloying and refining operations. In this manner both furnaces may be constantly utilized in the most eflicient Application filed January 6, 1925. Serial No. 809.

manner and their residual heat after tapping the charges may be used effectively. The

addition of an oxidizing agent in nominal quantities, more than sufiic'ient to effect the desired removal of impurities renders said additions independent of analysis, while the uncombined excess present in the slag is applied to useful purposeifor subsequent reduction Without the transfer thereof to another furnace and the consequent loss of heat and material. The conservation of furnace heat after tapping is largely aided by the residual bath left in the furnace; this residual bath,

moreover, acts as a. medium or carrier for the slag, which would otherwise adhereto the walls and bottom of the furnace and cause trouble in subsequent heats. It is also evident that by retaining in the furnace a portion of the bath in surface contact with the slag, there is very little possibility of slag 'ore in excess of their requirements, said operations being performed successively in two electric furnaces. afurnace for reduction and a furnace for alloying and refining, the reduction furnace for one charge performing the' function of a refining furnace for the subsequent charge, while the refining furnace for the former performs'the functions of a reduction furnace for the latter, whereby the excess'ore remaining in the slag of one refining operation is conserved in the furnace for subsequent re'ductionwith another charge.

2. An improvement in a duplex process for] I the manufacture ofsteel alloys which consists in reducing anaore containing the alloying element with an; excess of. a reducing agent in an electric furnace, whereby said ex- 4 cess is substantially introduced into the reduction product, discarding the reduction slag, adding the reduction product to a molten charge of refined steel in a second electric furnace, adding thereto a further charge of the ore in excess of that required to oxidize the undesired silicon and carbon contained therein, tapping a major portion of the refined steel alloy from the furnace, retaining the remaining portion thereof and the supernatant slag in the furnace to serve as the initial charge for a subsequent reduction stage, and transferring the product of said subsequent reduction to a molten bath of refined steel prepared in the first mentioned electric furnace 3. improvement in the manufacture of chromium steels low in carbon and in silicon,

- which consists in reducing chrome ore in an electric furnace with an excess of ferrosillcon, so as to obtain a ferro-chromium alloy containing a substantial proportion of con, discarding the reduction slag, transferring the reduction product. to a second furnace containing a charge of molten low carbon steel scrap, adding thereto chrome ore to oxidize the undesired residual silicon present in the alloyed steel, the chrome ore of said addition being in substantial excess of that red for oxidation, removing the major portion of the refined steel alloy for pom-mg into molds, and retaining in the furnace the remainder of the bath with its supernatant chromiferous sla to form an initial fusion bath for a succee g reduction charge.

4. A process for the manufacture of chrome steel alloys which consists in reducing sufiicient chrome ore with ferrosiliconin moderate excess of reduction requirements, so as to obtain therefrom the major portion of the chromium desired in the steel, separately 7 tion stage and for the alloying and refining 'vely, whereby the excess'chrome stage preparing a bath of low carbon steel, combmmg the latter with the reduction product and oxidizin the undesired residual silicon in the allo e steel by the addition of chrome ore in m erate excess of the residual silicon requirement, saidoperations being performed in two electric furnaces successively, alternating in successive'heats for the'reducore remaining in the ofthe re stage may be conserved for a dition to the c me ore charge of a subsequent reduction heat.

.In testimony whereof -I hereunto aflix my signature this 22nd daof December, 1924. NBY C. BIGGE.

In testimony whereof I hereunto aflix'my' signature this 22nd day of December 1924.

PERCY G. PARIS. 

